Heat seal interface for a disposable medical fluid unit

Abstract

A method, system and apparatus for performing peritoneal dialysis are provided. To this end, in part, a manifold for a medical fluid unit including at least one flexible membrane is provided. The manifold includes a plastic body defining an aperture, a fluid pathway communicating with the aperture and at least partially defined by the plastic body, and at least one port extended from the plastic body and communicating with the aperture. The port has a thickness and defines an opening, wherein at least a portion of the thickness is tapered and at least a portion of the tapered portion is heat sealed to the membrane.

The invention is claimed as follows:  
     
         1 . A manifold for a medical fluid unit including at least one flexible membrane, the manifold comprising: 
 a plastic body defining an aperture;    a fluid pathway communicating with the aperture and at least partially defined by the plastic body; and    at least one port extended from the plastic body and communicating with the aperture, the port having a thickness and defining an opening, wherein at least a portion of the thickness is tapered, at least a portion of the tapered portion being heat sealed to the membrane.    
     
     
         2 . The manifold of  claim 1 , wherein the tapered portion includes first and second surfaces that are each seal to a membrane.  
     
     
         3 . The manifold of  claim 1 , wherein the plastic body includes at least one side wall having a thickness, wherein at least a portion of the thickness of the side wall tapers, the tapered portion of the side wall being heat sealed to at least one membrane.  
     
     
         4 . The manifold of  claim 1 , wherein the plastic body includes at least one non-tapered side wall.  
     
     
         5 . The manifold of  claim 1 , wherein the thickness tapers along first and second surfaces, wherein the surfaces converge to form an edge.  
     
     
         6 . The manifold of  claim 5 , wherein the thickness tapers to an edge line.  
     
     
         7 . The manifold of  claim 1 , wherein the tapered portion includes a raised bead of plastic that deforms upon heating.  
     
     
         8 . The manifold of  claim 1 , wherein the thickness is generally elliptical in cross-section.  
     
     
         9 . The manifold of  claim 1 , wherein the port defines a non-circular opening.  
     
     
         10 . The manifold of  claim 1 , wherein the port defines an elliptical opening.  
     
     
         11 . A manifold for a disposable medical fluid unit, the unit being sealed to at least one flexible membrane, the manifold comprising: 
 a plastic body defining at least a portion of a fluid pathway; and    at least one side wall of the plastic body having a thickness, wherein at least a portion of the thickness is reduced, at least a portion of the reduced thickness portion being heat sealed to the at least one membrane.    
     
     
         12 . The manifold of  claim 11 , wherein the reduced thickness tapers from top and bottom edges of the side wall.  
     
     
         13 . The manifold of  claim 12 , wherein the tapered thickness converges to form an edge line.  
     
     
         14 . The manifold of  claim 11 , wherein the plastic body is semi-rigid.  
     
     
         15 . The manifold of  claim 11 , wherein the reduced thickness is continuous along the side wall.  
     
     
         16 . The manifold of  claim 11 , wherein the reduced thickness discontinues along the side wall allowing at least one fluid connection port to extend from the side wall.  
     
     
         17 . The manifold of  claim 11 , wherein the reduced thickness includes a raised bead of plastic that deforms upon heating.  
     
     
         18 . A disposable unit for a medical fluid system comprising: 
 a manifold including at least one side wall having a thickness, wherein at least a portion of the thickness is reduced;    a plurality of membranes heat sealed to portions of the reduced thickness portion;    at least one port extended from the side wall and defining an opening, the port having a noncircular cross-sectional shape and being heat sealed to the at least one membrane; and    a fluid path formed by the membranes and the manifold.    
     
     
         19 . The disposable unit of  claim 18 , wherein the fluid path is a first fluid path, and wherein the membranes seal to one another to form a second fluid path.  
     
     
         20 . The disposable unit of  claim 19 , wherein the first fluid path communicates with the second fluid path.  
     
     
         21 . The disposable unit of  claim 19 , wherein the second fluid path is a spiral wound fluid heating path.  
     
     
         22 . The disposable unit of  claim 18 , wherein the membranes seal together to form a pump receptacle that communicates with the port.  
     
     
         23 . A method of manufacturing a disposable medical fluid unit comprising the steps of: 
 forming a manifold of a thickness and reducing the thickness in at least a portion of the manifold; and    sealing a plurality of membranes to the reduced thickness portion of the manifold and sealing a portion of the membranes to one another.    
     
     
         24 . The method of  claim 23 , wherein sealing the membranes to the manifold and to one another includes heat sealing.  
     
     
         25 . The method of  claim 23 , wherein reducing the thickness includes tapering the thickness of the manifold.  
     
     
         26 . A dialysis system comprising: 
 a hardware unit; and    a disposable unit fluidly coupled to a supply line, a drain line and a patient line, the disposable unit including: (i) a pump receptacle, (ii) at least one flexible membrane, (iii) a plastic body defining an aperture, (iv) a fluid pathway communicating with the aperture and at least partially defined by the plastic body, and (v) at least one port extended from the plastic body and communicating with the aperture, the port having a thickness and defining an opening, wherein at least a portion of the thickness is tapered, the tapered portion heat sealed to the at least one membrane, and wherein the hardware unit and the receptacle form a pump chamber.